The application requires the priority of No. 61/365837, the U.S. Patent application submitted on July 20th, 2010, and the full content of this application comprises in this application by reference.
Summary of the invention
In an embodiment of first aspect present invention, a kind of compressible ground mat with two conductor layers that separated by the compressible foam layer is provided, described pad comprises:
The first conductor layer, Copper Foil for example, described the first conductor layer have first relative (top) and second (end) face surface (facial surface);
The first adhesive phase, described the first adhesive phase has first relative (top) and second (end) face is surperficial, the described end face surface of described the first adhesive phase directly contacts with the part of the described bottom surface of described the first conductor layer, and described the first conductor layer extends to outside described the first adhesive phase;
Froth bed, described froth bed have first relative (top) and second (end) face is surperficial, and the described end face of described froth bed is surperficial directly to be contacted with the described bottom surface of described the first adhesive phase;
The second adhesive phase, described the second adhesive phase have first relative (top) and second (end) face is surperficial, and the described end face of described the second adhesive phase is surperficial directly to be contacted with the described bottom surface of described froth bed;
The second conductor layer, Copper Foil for example, described the second conductor layer has first relative (top) and second (end) face is surperficial, the part on the described end face surface of described the second conductor layer directly contacts with the described bottom surface of described the second adhesive phase, described the second conductor layer extends to outside described the second adhesive phase, makes the part of the described bottom surface of the part on described end face surface of described the second conductor layer and described the first conductor layer connect;
The 3rd adhesive phase of conduction, described the 3rd adhesive phase have first relative (top) and second (end) face is surperficial, and the described end face of described the 3rd adhesive phase is surperficial directly to be contacted with the described bottom surface of described the second conductor layer; And
(optional) release liner (release liner) of choosing wantonly, described release liner has first relative (top) and second (end) face is surperficial, and the described end face of described release liner is surperficial directly to be contacted with the described bottom surface of described the 3rd adhesive phase.
Described the first and second conductor layers can connect each other by any in a plurality of means of different such as welding, soldering, electroconductive binder, machanical fastener.Described the first and second adhesives and described foam are typically and preferably nonconducting.
In another embodiment of a first aspect of the present invention, a kind of compressible ground mat with a conductor layer and a compressible foam layer is provided, described pad comprises:
Conductor layer, Copper Foil for example, described conductor layer have first relative (top) and second (end) face surface;
The first adhesive phase, described the first adhesive phase has first relative (top) and second (end) face is surperficial, the described end face surface of described the first adhesive phase directly contacts with the part of the described bottom surface of described conductor layer, and described conductor layer extends to outside described the first adhesive phase;
Froth bed, described froth bed have first relative (top) and second (end) face is surperficial, and the described end face of described froth bed is surperficial directly to be contacted with the described bottom surface of described the first adhesive phase;
The second adhesive phase of conduction, described the second adhesive phase has first relative (top) and second (end) face is surperficial, the part on the described end face surface of described the second adhesive phase directly contacts with the described bottom surface of described froth bed, described the second adhesive phase extends to outside described froth bed, makes the part of the described bottom surface of the part on described end face surface of described the second adhesive phase and described conductor layer connect; And
Optional release liner, described release liner have first relative (top) and second (end) face is surperficial, and the described end face of described release liner is surperficial directly to be contacted with the described bottom surface of described the second adhesive phase.
Described conductor and the second adhesive phase connect each other by the operation of nature of described the second adhesive phase.Described the first adhesive and described foam are typically and preferably nonconducting.
In an embodiment of a second aspect of the present invention, provide a kind of structure to have the method for the compressible ground mat of two conductor layers that separated by the compressible foam layer, said method comprising the steps of:
First conductor layer that will have first and second relative surfaces is attached to the compressible foam layer that also has first and second relative surfaces, make described second surface of (1) described first conductor layer be attached to the described first surface surface of described froth bed, and (2) described the first conductor layer extends to outside described froth bed, to form the extension of described the first conductor layer that is not attached to described froth bed;
Second conductor layer that will have first and second relative surfaces is attached to described compressible foam layer, make the described first surface surface of (1) described second conductor layer be attached to described second surface of described froth bed, and (2) described the second conductor layer extends to outside described froth bed, to form the extension of described the second conductor layer that is not attached to described froth bed; And
The described first surface surface of the described extension of described second surface of the described extension of described the first conductor layer and described the second conductor layer is connect.
Described the first and second conductor layers preferably are attached to described froth bed by PSA.The described extension of described the first and second conductor layers preferably connects each other by welding, soldering, adhesive or machanical fastener.
In another embodiment of a second aspect of the present invention, provide a kind of structure to have the method for the compressible ground mat of a conductor layer and a compressible foam layer, said method comprising the steps of:
The conductor layer that will have first and second relative surfaces is attached to the compressible foam layer that also has first and second relative surfaces, make described second surface of (1) described conductor layer be attached to the described first surface surface of described froth bed, and (2) described conductor layer extends to outside described froth bed, to form the extension of the described conductor layer that is not attached to described froth bed;
The conductive adhesive layer that will have first and second relative surfaces is attached to described compressible foam layer, make the described first surface surface of (1) described conductive adhesive layer be attached to described second surface of described froth bed, and (2) described conductive adhesive layer extends to outside described froth bed, to form the extension of the described conductive adhesive layer that is not attached to described froth bed; And
The described first surface surface of the described extension of described second surface of the described extension of described conductor layer and described conductive adhesive layer is connect.
Described conductor layer preferably is attached to described froth bed by PSA, and the described extension of described conductor layer.
Embodiment
Suggest unless otherwise indicated, from the context or this area in convention, otherwise all parts and percentage all are based on weight, and all method of testings are all the universal method of the disclosure when submitting to day.According to the United States Patent (USP) convention, the full content of any patent, patent application or the communique of quoting (perhaps its United States version that is equal to), particularly about the general knowledge in synthetic technology, product and Treatment Design, polymer, catalyst, definition (with the inconsistent scope of the definition that specifically provides in the disclosure) and this area, comprise in this application by reference.
Numeral and digital scope in the disclosure are similar to, and therefore unless otherwise noted, otherwise can comprise this scope value in addition.If there is the interval of at least two units between any lower limit and any higher value, digital scope comprise from lower limit and higher limit and comprise higher limit and lower limit itself, with all values of an incremented.As an example, if composition, physics or other characteristics, for example, thickness, percentage by weights etc. are from 100 to 1000, are intended that to enumerate clearly as all individual values such as 100,101,102, and as 100 to 144,155 to 170,197 to 200 subranges such as grade.For comprising less than 1 value or comprising scope (for example, 0.01,0.1,1.1 etc.) greater than 1 mark, a unit according to circumstances is considered to 0.001,0.01 or 0.1.For the scope (for example, 1 to 5) that comprises less than 10 unit numbers, a unit example ground is considered to 0.1.These are only the examples that provides expressly, and all possible combinations of values all is considered to clearly be explained in the disclosure between the minimum of enumerating and peak.In addition, the digital scope in the disclosure and value are to provide for the size of pad with layer.
No matter whether open especially, the terms such as " comprising ", " comprising ", " having " are not intended to get rid of the existence of supplementary element, step or program.For fear of query, unless otherwise indicated, otherwise by using term " to comprise " that all the components of advocating can comprise one or more supplementary element contents, part and/or material.On the contrary, term " must by ... consist of " got rid of any other parts, step or program from any scope of enumerating subsequently, will not be that operability is necessary except those.Term " by ... consist of " got rid of any parts, step or the program that do not specifically describe or list.Unless otherwise indicated, otherwise the term "or" refers to individual or any combination of listed member.
" face surface ", " flat surfaces ", " top surface ", " basal surface " etc. use with " edge surface " with distinguishing.If the shape of rectangle or configuration, layer will comprise that two relative faces that connect by four edge surfaces (relative two edges surfaces, every pair with another to intersecting at a right angle) are surperficial.If circular configuration, this layer will comprise two relative face surfaces that connect by a continuous edge surface.Described layer can be any size and dimension, and therefore described flat surfaces and edge surface can be also any size and dimensions, for example, thin or thick, polygonal or circular, flat or wavy etc.
The meaning of the term such as " contact adhesive ", " PSA " is: engages and form contrast, join to as the result of applied pressure and apply surperficial adhesive to form solid material with evaporation or lyosoption.
The meaning of the terms such as " directly contact ", " close contact " is: two surfaces or layer be physical contact each other, thus form do not have in the middle of or the interface of intermediary layer or material.
The ground mat that comprises two conductor layers
Fig. 2 is the schematic diagram with compressible ground mat of two conductor layers that separated by the compressible foam layer.Compressible ground mat 20 comprises the first conductor layer 21, and this first conductor layer 21 has relative first or end face surface 21a and second or bottom surface 21b.Conductor 21 can comprise any electric conducting material, but typically comprises copper or aluminium.Typically and preferably, conductor 21 is Copper Foils.Typically and preferably, conductor 21 have 5 to 100 microns (μ m), more typically be 20 to 50 microns, be more typically the thickness of 18 to 25 microns again.
First or the end face surface 22a of the part of bottom surface 21b and the first adhesive phase 22 directly contacts, and this first adhesive phase 22 can comprise any adhesive that the first conductor 21 and foam 23 is both all shown excellent bonds.Typically, this adhesive is PSA.These adhesives are well known in the art, can extensively obtain, and include but not limited to based on elastomeric PSA, based on the PSA of natural rubber with based on the PSA of acrylic acid (acrylic).The use of can using separately or be bonded to each other of these adhesives.Preferred PSA is based on acrylic acid, comprises the polymer as the alkane ester of the acrylic or methacrylic acid of main component.This adhesive typically but must not be nonconducting.Typically and preferably, the first adhesive phase have 10 to 100 microns (μ m), more typically be 35 to 80 microns, be more typically the thickness of 35 to 50 microns again.
Bottom surface 22b directly contacts with first or the end face surface 23a of foam 23, and this foam 23 can comprise any material that shows the good compression characteristic.Representational foam includes but not limited to polyurethane, polyolefin (for example, polyethylene, polypropylene, polyisoprene etc.), natural and synthetic rubber etc.This foam is nonconducting typically, typically and preferably has 0.3 to 10 micron (μ m), is more typically 0.5 to 2 micron, then is more typically the precommpression thickness of 0.5 to 1 micron.Compress that the required power of this foam is at least part of depends on the grade of foam and the final application of this ground mat.Typically, this foam can be defeated half that is reduced to less than its precommpression thickness by minimal compression.
Bottom surface 23b directly contacts with the end face surface 24a of the second adhesive phase 24.Typically but be not necessarily, the second adhesive phase 24 has identical composition and thickness with the first adhesive phase 22.
The part of the end face surface 25a of bottom surface 24b and the second conductor 25 directly contacts, and this second conductor 25 typically but must not have identical composition and thickness with the first conductor layer 21.The first and second conductor layers 21 and 25 both all extend to outside their adjacent adhesive phases 22 and 24 separately enough far away, to such an extent as to form such extension: this extension (1) does not directly contact with 24 with adhesive phase 22, and any means easily that (2) can pass through for example welding, soldering, electroconductive binder, machanical fastener (for example, rivet, clip etc.) connect each other.The connection of these two conductor layers makes the bottom surface 21b of (1) first conductor layer 21 be attached to the end face surface 25a of the second conductor layer 25, and (2) electric current can flow to another conductor from a conductor substantially unblockedly.
Bottom surface 25b directly contacts with the end face surface 26a of the 3rd adhesive phase 26.The 3rd adhesive phase 26 is PSA typically and preferably also, yet is the PSA of conduction.The composition of these adhesives can be with the first and second adhesives identical, but for example be filled with the conductive particles such as copper or aluminum metal, conducting polymer materials.The 3rd adhesive phase enough conducts electricity, to such an extent as to will be from any current delivery of the second conductor layer to it by the accompanying substrate surface (not shown) that arrives of bottom surface 26b.The 3rd adhesive phase typically and preferably have 10 to 150 microns (μ m), more typically be 35 to 100 microns, be more typically the thickness of 35 to 50 microns again.
Before ground mat 20 was ready to use, adhesive phase 26 randomly and was preferably protected by release liner.Bottom surface 26b typically and preferably directly contacts with the end face of release liner (not shown) is surperficial.Release liner is as known in the art, and representational example includes but not limited to utilize such as based on glassine paper and plastic film after the release-agent-treated (for example spraying) of the releasing agent of silicone.
The ground mat that comprises a conductor layer
Fig. 3 is the schematic diagram with compressible ground mat of a conductor layer and a compressible foam layer.Compressible ground mat 30 comprises having relative first or end face surface 31a and second or the conductor layer 31 of bottom surface 31b.Conductor 31 can comprise any electric conducting material, but typically comprises copper or aluminium.Typically and preferably, conductor 31 is Copper Foils.Typically and preferably, conductor 31 have 5 to 100 microns (μ m), more typically be 20 to 50 microns, be more typically the thickness of 18 to 25 microns again.
First or the end face surface 32a of the part of bottom surface 31b and the first adhesive phase 32 directly contacts, and this first adhesive phase 32 can comprise any adhesive that the first conductor 31 and foam 33 is both all shown excellent bonds.Typically, this adhesive is PSA, and is used for adhesive phase 22,24 and 26 as mentioned above.This adhesive is nonconducting typically.Typically and preferably, adhesive phase 32 have 10 to 100 microns (μ m), more typically be 35 to 80 microns, be more typically the thickness of 35 to 50 microns again.
Bottom surface 32b directly contacts with first or the end face surface 33a of foam 33, and as foam 23, foam 33 can comprise any material that shows the good compression characteristic.Representational foam includes but not limited to polyurethane, polyolefin (for example, polyethylene, polypropylene, polyisoprene etc.), natural and synthetic rubber etc.This foam is nonconducting typically, typically and preferably has the precommpression thickness of 0.3 to 10 micron (μ m), is more typically 0.5 to 2 micron, then is more typically 0.5 to 1 micron.Compress that the required power of this foam is at least part of depends on the grade of foam and the final application of this ground mat.Typically, this foam can be defeated half that is reduced to less than its precommpression thickness by minimal compression.
The bottom surface 33b of foam 33 directly contacts with the end face of electrically-conducting adhesive layer 34 surface 34a.The composition of this adhesive can be identical with adhesive phase 32, but be filled with conductive particles such as copper or aluminum metal, conducting polymer materials.Adhesive phase 34 enough conducts electricity, to such an extent as to will be from any current delivery of the second conductor layer to it by the accompanying substrate surface (not shown) that arrives of bottom surface 34b.Adhesive phase 34 typically and preferably have 10 to 100 microns (μ m), more typically be 35 to 80 microns, be more typically the thickness of 35 to 50 microns again.
Conductor layer 31 and conductive adhesive layer 34 both extend to separately adjacent adhesive phase 32 and foam 33 outside enough far away, to such an extent as to form such extension: this extension (1) does not directly contact with foam 33 with adhesive phase 32, and (2) can connect each other, make the bottom surface 31b of (a) conductor layer 31 be attached to the end face surface 34a of adhesive phase 34, and (b) electric current can flow to this electroconductive binder from this conductor substantially unblockedly.
Before ground mat 30 was ready to use, adhesive phase 34 randomly and was preferably protected by release liner.Bottom surface 34b typically and preferably directly contacts with the end face of release liner (not shown) is surperficial.
The structure that comprises the ground mat of two conductor layers
Shown in Fig. 4, structure has a method of the compressible ground mat of two conductor layers that separated by the compressible foam layer.The method comprises the following steps:
First conductor layer 21 that will have first and second relative surfaces is attached to the compressible foam layer 23 that also has first and second relative surfaces, make second surface of (1) first conductor layer be attached to the first surface surface of this froth bed, and (2) first conductor layers extend to outside this froth bed, to form the extension of the first conductor layer that is not attached to this froth bed;
Second conductor layer 25 that will have first and second relative surfaces is attached to compressible foam layer 23, make the first surface surface of (1) second conductor layer be attached to second surface of this froth bed, and (2) second conductor layers extend to outside this froth bed, to form the extension of the second conductor layer that is not attached to this froth bed; And
The first surface surface of the extension of second surface of the extension of the first conductor layer 21 and the second conductor layer 25 is connect.
Use any in numerous technology as known in the art, by any suitable means, typically be welding, these two conductor layers are attached to this froth bed by the adhesive (not shown), and these two conductor layers are connect each other.Can also this adhesive be applied to described conductor and/or foam by any in numerous distinct methods, but typically, at first by applying or spraying is applied to this foam with this adhesive, described conductor is contacted with the adhesive on this foam.For conductor layer 25, can before or after being attached to foam 23 and/or conductor layer 21, its (conductor layer 25) apply electroconductive binder (26 in Fig. 2).Typically, the release liner (not shown) covers this electroconductive binder, and then it is applied to conductor layer 25.In case the sheet material of ground mat 20A is configured out, just by producing a plurality of independent ground mats (20 in Fig. 2) along this sheet material of die cut lines 27 cross cuttings.These ground mats can be cut into any size and the configuration of the layer configuration that keeps Fig. 2.
The structure that comprises the ground mat of a conductor layer
Shown in Fig. 5, structure has a method of the compressible ground mat of a conductor layer and a compressible foam layer, and the method comprises the following steps:
The conductor layer 31 that will have first and second relative surfaces is attached to the compressible foam layer 33 that also has first and second relative surfaces, make second surface of (1) conductor layer 31 be attached to the first surface surface of froth bed 33, and (2) conductor layer 31 extends to outside froth bed 33, to form the extension of the conductor layer 31 that is not attached to froth bed 33;
The conductive adhesive layer 34 that will have first and second relative surfaces is attached to compressible foam layer 33, make the first surface surface of (1) conductive adhesive layer 34 be attached to second surface of froth bed 33, and (2) conductive adhesive layer 34 extends to outside froth bed 33, to form the extension of the conductive adhesive layer 34 that is not attached to froth bed 33; And
The first surface surface of the extension of second surface of the extension of conductor layer 31 and conductive adhesive layer 34 is connect.
This conductor layer is attached to this froth bed by the adhesive (not shown), and the effect of this conductor layer by this adhesive is attached to this electroconductive binder.Can this adhesive be applied to described conductor and/or foam by any in numerous distinct methods, but typically, at first by applying or spraying is applied to this foam with this adhesive, described conductor is contacted with the adhesive on this foam.Can before or after being attached to foam 33, conductor layer 31 apply electroconductive binder 34.Typically, the release liner (not shown) covers this electroconductive binder, and then it is applied to froth bed 33.In case the sheet material of ground mat 30A is configured out, just by producing a plurality of independent ground mats (30 in Fig. 3) along this sheet material of die cut lines 27 cross cuttings.These ground mats can be cut into any size and the configuration of the layer configuration that keeps Fig. 3.
Comprise that for structure the method for the present invention of the ground mat of one or two conductor layer and a compressible foam is very efficiently and has very expensive efficient.They minimize the conductor waste, and for example, they have exempted the diagonal angle leg 11b in Fig. 1, and they allow to produce a large amount of ground mats with relatively few step.They also allow to produce very thin product, and this is because the hardness of the compressibility of this pad and conductor layer or thickness are irrelevant.On the contrary, compressibility is the function of foam.This allows the physical characteristic by changing foam rather than changing this pad by changing the tool of production conversely.
Ground mat of the present invention especially is used to the shielding part of conduction is connected to electrically.When the matching surface of the electronic equipment that size is not met just (size for example just do not meet two surfaces in gap, space and space and this together with form) when coordinating, usually needs this conductive interface.This is common in the electric devices such as cell phone, calculator, instant message transrecieving device, camera.Compressible ground mat of the present invention is filled these gaps, space etc. when compression.In addition, when compression, the conductivity of this electroconductive binder increases, because the conductive particle in this adhesive is close to each other.
Although utilize specific detail to describe the present invention by above-mentioned specific embodiment, this details is mainly used in exemplary purpose.In the situation that do not depart from the spirit and scope of the present invention defined in the appended claims, those skilled in the art can carry out variations and modifications.